Vikas Dabeer Director- Business Development Applied Materials India Pvt. Ltd India

Transcription

1 Vikas Dabeer Director- Business Development Applied Materials India Pvt. Ltd India

2 Applied Materials Global Strength APPLIED MATERIALS INC Market Cap: $29.16 billion Fiscal 2014 Revenue: $9.1 billion Fiscal 2014 R&D: $1.4 billion Founded: November 10, 1967 Headquarters: Santa Clara, California Global Presence: Fortune 500 Ranking: 302 RD&E and/or Manufacturing Centers: 84 locations in 18 countries China, Germany, India, Israel, Italy, Singapore, Taiwan, United States Employees: ~13,700 worldwide Patents: ~10,400 issued APPLIED MATERIALS INDIA PVT LTD Founded: June, 2002 Headquarters: Bangalore, India Presence: Bangalore, Chennai, Delhi, Mumbai Lab Space: > 25,600 sq. ft. University Spend: > INR 75 CR Employees * : ~ *2300 Data as of Oct 7 th 2014 *Including RFTs, contractors & associates

3 Commercial FCL Progress Installed 2 SCFCL into the grid (US). Limited 15 faults. Systems have 100% uptime. Introduced solid state fault current limiter (SSFCL) Medium voltage system Flexible modular approach Installed a SSFCL into the grid in Ausnet (Australia) Contract with Asian Customer for 2 Transmission class FCL First Commercial Sales In final contract negotiations for 3 separate site installs of SCFCL s and SSFCL s (total of 6 fault current limiters). In funding approval for a 220KV FCL system in India In discussions with customers for up to 500 KV fault current solutions 115 KV FCL Commission 3/16

4 Isometric View

5 Drivers of the Fault problems Generation Transmission Distribution Customers Increased Fault Current Level New Generation Renewable energy wind, solar, hydro Increased grid interconnection Increased demand Urbanization - Population growth Transportation - Electric cars, trains Economic Growth and Large Investments in Distributed Generation are driving new Grid Architectures. Fault currents are rising

6 Fault Currents are Destructive Large fault currents can cause the grid to fail catastrophically Even small fault currents can damage the grid s capital infrastructure Age equipment Premature failures Performance degradation

7 Scenarios for use of FCLs Driver SCFCL Role Benefit to customer Increase Substation Capacity Limit FC on system and allow more generators to be connected Defer capital expenditures on new substation or Equipment Interconnect new generation Limit FC created by new generators Higher utilization of assets Increase efficiency Protect Key Assets Interconnect Distributed Generators A More Reliable and Resilient Grid Protect transformers or circuit breakers from FC and extend key asset life Limit FC on transformers Allow more power flow in parallel Enable closing of Bus Ties, interconnect Substations Tightly Meshed Grid for increased Power Reliability and resiliency Reduce Repair and Maintenance cost and downtime Facilitate integration of distributed/ localized generation ( solar, wind micro-hydel etc.) More reliable and strong grid increasing options to deliver high quality power

8 Current options to mitigate Fault Currents Utility over-engineer system Introduce mitigations with detrimental impact Bus Splitting ($$) Mitigations High impedance transformers ($$$) Current Limiting Reactors ($$) Impact Reduces flexibility and reliability Increases transformer cost and losses Increases active and reactive power loss, voltage drops causing voltage stability issues Breaker & Busbar Upgrades ($$) High sub-station down-time and cost New Substations ($$$$) High cost of land & new cable lines Current Solutions are non-optimum and may require additional mitigation

9 System Benefits of Fault Current Limiters Applied Materials FCL neutralizes the effects of fault current on grid architecture Since fault currents dictate much of the grid design and equipment configuration today, neutralizing fault currents creates greater flexibility in grid design and component selection enabling: Safety, Arc Flash Reduction, Brush Fire Suppression Increased substation capacity Easier addition of new generation Protecting key assets Easier interconnection of distributed generation A more reliable and resilient grid

10 Current Fault Inception Fault Clearing Desired Characteristics of an Ideal FCL An Ideal Fault Current Limiter would In normal operation, it is virtually "transparent (no power or voltage loss) to the network Increase the impedance on the line well before the first fault peak (when the most damage occurs) Diminish the fault current by at least a factor of 2 for its duration Return the source impedance to its original value What is needed is a system that can move the electrical power from one circuit to another At lower power: Solid State At higher Power: Superconductivity Typical current waveforms due to fault Normal Operation Fault Without FCL (Prospective Fault Current) td (Fault duration time) Recovery tr (recovery ti Normal Load Current Prospective Fault Current Limited Fault Curre Fault Current Limiters reduce Fault Currents Without the Need for Mitigation

11 Applied Materials Fault Current Limiter Platforms Transmission System FCL Superconducting Fault Current Limiter (SCFCL) 66 kv to 230 kv transmission voltage levels > 1000 A load current Up to 50 % or higher fault current reduction Distribution System FCL Solid State Fault Current Limiter (SSFCL) Superconducting Fault Current Limiter If required Up to 45 kv distribution voltage levels > 1000 A load current Up to 50 % or higher fault current reduction Shunt Reactor, Z SH = R SH + j X SH I SH SC unit I SC Superconductor Unit Z SC = R SC + j X SC SCFCL Shunt Reactor, Z SH = R SH + j X SH I SH SS unit I SS Solid State Unit Z SS = R SS + j X SS SSFCL

12 How an SCFCL works Shunt Reactor Zsh = Rsh + j Xsh CB1 Transformer Substation CB2 SC unit Superconductor Unit Z SC = R SC + j X SC CB3 Short Circuit Fault Load Z S = R S + j X S Fault current Generator Normal operation Load current flows through superconducting unit SCFCL introduces nearly zero impedance and zero voltage drop Fault Condition Superconductor inherently senses fault current, quenches, inserts high resistance in ~ 1 ms Current transfers to shunt and limits fault current Recovery Superconducting unit recovers superconducting state quickly (seconds) Fault detection and current limiting is done with passive inherent properties laws of physics rather than electronics superconductor

13 How a SSFCL works Uses Solid state power electronics (IGBT s) instead of Superconducting tape Does not require liquid nitrogen cooling Uses proprietary design concepts for Current, Voltage and Thermal management In normal operation Z SS << Z SH During fault j X SS increases and the current flows through the shunt reactor Shunt Reactor, Z SH = R SH + j X SH I SH I SS SSFCL SS unit Solid State Unit Z SS = R SS + j X SS

14 Testing Methodology Sub-System Validation and Test Validate lab findings at a system level Understand Physics / Component Engineering and Test iterations of designs; 1000 s of faults Development of design guidelines Failure mode validation and coverage Expose and correct any/all system level issues Full System Validation Full system testing and validation at utility power levels Customer requirement testing Multiple Labs Enable Fast, Efficient Development and Learning

15 Fault Current Limiter Testing Performance Tested and qualified at 230 KV. 5 Weeks of KEMA Testing Lifetime Tested for 200 Bus Faults (>40 Years) KEMA 1 Architecture Validation The FCL works as designed (Performance envelope to 125KV, 56 ka and 60 % Reduction) KEMA 2 System Performance Controls, User Interface and refrigeration integration validated KEMA 3 Life testing and Customer Validation (>200 Fault Test) KEMA 4 Component Characterization KEMA 5 Product Platform Validation and System Optimization

16 Voltage [kv] Current [ka] Actual KEMA Test Results KEMA Test Trial # kv and 56 ka rms (150 ka peak) Prospective Fault Current, limited to 24 ka rms (65 ka peak), 56 % Current Reduction Fast response time < 1 ms 1st peak limitation 90% of Fault current flows through Shunt and only 10% flows through SC unit - Shunt protects SC unit Time [ms] Total Limited Fault Current[kA] SC Current [ka] Shunt Current [ka] Voltage [kv] st peak response within ~ 1 ms response time.

17 Current [ka], Voltage [kv] Current [ka], Voltage [kv] Validation of Simulation Results KEMA Test Simulation 175 KEMA Test Trial # kv and 56 ka rms (150 ka peak) Prospective Fault Current, limited to 24 ka rms (65 ka peak), 56 % Current Reduction 175 Simulation 12.5 kv and 56 ka prospective fault current Simulation - KEMA test SCFCL, 72 m x 6 tapes, Zsh = 264 m.ohm, Vs = 12.5 kv and 56 ka (rms) Prospective Fault Current = Time [ms] Prospective Fault Current [ka] Limited Current[kA] Superconductor Current [ka] Shunt Current [ka] Voltage [kv] Time [ms] Prospective Fault Current [ka] Limited Current [ka] Superconductor Current [ka] Shunt Current [ka] Voltage [kv] Current Limiting Performance Test Results Agree with Simulation Results

18 Transmission Impulse test results

19 SCFCL Reliability Tree SCFCL Facilities Module (77 Refrigerator) FCL Module Redundancy Control System Transfer Lines Transfer Lines Buffer Cryostat Stirling SPC4 Cryo Engine Buffer Cryostat Metrology Buffer Cryostat Metrology Valve and Pumping System Valve and Pumping System Latency Protection Redundancy Redundancy Bushings Matrix Assembly Shunt Assembly FCL Cryostat FCL Metrology FCL Metrology Demonstrate Reliability Redundancy Subsystems with Latency or Redundancy are protected. Need to focus on 4 key subsystems

20 SCFCL on-grid demonstration Applied Materials Superconducting FCL installed on Central Hudson Gas and Electric Company in New York State. System image at Sub station- June 9 14 System successfully installed, and online in June System has demonstrated fault current capture and mitigation 15 times over past 1 year

21 Fault Captured on July 8, Detail 4 Fault Clears Back to normal! 1 2 All is well 30 amp through unit Fault occurs SC current raises to 1000A and Shunt to 500A (4ms) Voltage Across Device Current Through SC Path Current Through Shunt 3 Next ½ cycle SC unit gets more resistive SC unit is now less current than Shunt (2500A vs. 3750A)..current now shifted to limiting device System Works and Clearly Shows System Operation / Performance

22 FCL Design Tradeoffs / Sensitivities Major Items Influencing System Design are: 1. System Voltage 2. System Normal Current 3. Current Limiting Required Each system requirement has system impacts: System Voltage Normal Current System voltage and limiting required determine the voltage drop across the FCL during fault FCL must be designed to handle that current full time SC Unit Size Increased Cryo-loading Bulk Active Tank Size # of Refrigerators Tank Volume, Fill Frequency, Available Latency Limiting Required FCL adds impedance during fault. This translates to a Vdrop across the FCL Reactor Size (Z FCL ) Voltage Drop Required

23 Customer Inputs for FCL System Design Selected Site Name / Location Requirement Values Comments System Voltage (3 phase Line-to-Line) Power System kvrms Load Current Continuous / Maximum / Arms System MVA Continuous / Maximum / MVA Prospective Fault Current - Symmetric Ratio of Fault current to Max load current (Fault C/Max Load) Fault Duration Before Protection System Acts Fault & Recovery Required Fault Current Reduction 1 st peak % Required Limited Fault Current - Symmetric Impulse Voltage (BIL) Rating Requirement Switching Re-closure Sequence and Timing karms Cycles karms kv Calculated by Applied Maintenance cycle at existing facility Site Selection and Logistics

24 Contact details: Phone: Phone: